Gas exhaust system for a mask apparatus for use in a breathing assistance system

ABSTRACT

A gas exhaust system for a mask apparatus for use in a breathing assistance system may include a housing for supporting a cushion configured to provide a seal against a patient&#39;s face, the housing defining a housing opening, and a ball member secured in the housing opening such that the ball member may rotate relative to the housing. One or more exhaust passageways for communicating exhaust gas away from the patient may be defined between an outer surface of the ball member and the housing opening.

TECHNICAL FIELD

The present disclosure relates generally to the field of breathingassistance systems, e.g., a gas exhaust system for a mask apparatus foruse in a breathing assistance system.

BACKGROUND

In recent years, continuous positive airway pressure (CPAP) therapy hasbecome a common prescription for individuals suffering from sleep apneaand/or other breathing ailments. Such therapy may involve placement of anose or face mask on the subject during sleeping, while positivepressure air is continuously delivered to the subject through the mask.The positive pressure air may be delivered to the patient's upper airwayvia a face mask or other patient interface in order to prevent the upperairway tissues from collapsing during sleep, thus reducing theoccurrence and/or severity of sleep apnea.

SUMMARY

In accordance with one embodiment of the disclosure, a gas exhaustsystem for a mask apparatus for use in a breathing assistance system mayinclude a housing for supporting a cushion configured to provide a sealagainst a patient's face, the housing defining a housing opening, and aball member secured in the housing opening such that the ball member mayrotate relative to the housing. One or more exhaust passageways forcommunicating exhaust gas away from the patient may be defined betweenan outer surface of the ball member and the housing opening.

In accordance with another embodiment of the disclosure, a breathingassistance system may include a gas delivery apparatus configured todeliver gas toward a patient, and a mask apparatus in fluidcommunication with the gas delivery apparatus. The mask apparatus mayinclude a gas exhaust system for exhausting gas away from the patient.the gas exhaust system may include a housing for supporting a cushionconfigured to provide a seal against a patient's face, the housingdefining a housing opening, and a ball member secured in the housingopening such that the ball member may rotate relative to the housing.One or more exhaust passageways for communicating exhaust gas away fromthe patient may be defined between an outer surface of the ball memberand the housing opening.

In accordance with another embodiment of the disclosure, a gas exhaustsystem for a mask apparatus for use in a breathing assistance system mayinclude housing means for supporting a cushion configured to provide aseal against a patient's face, the housing means defining a housingmeans opening, and ball means secured in the housing means opening suchthat the ball means may rotate relative to the housing means. One ormore exhaust communicating means for communicating exhaust gas away fromthe patient may be defined between an outer surface of the ball meansand the housing means opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example breathing assistance system for providingbreathing assistance to a patient, according to one embodiment of thedisclosure;

FIG. 2 illustrates an exploded view of a portion of mask apparatus,indicating the assembly of a housing, a ball member, and a mountingsystem to form a ball joint, according to one embodiment of thedisclosure;

FIG. 3 illustrates an example mask apparatus with a mounting platealigned for attachment to a housing, according to one embodiment of thedisclosure;

FIGS. 4A-4C illustrates a detailed view of an example securing memberand corresponding attachment member for securing a mounting plate to ahousing, according to one embodiment of the disclosure;

FIG. 5 illustrates the inside of a mask apparatus with a mounting platesecured to a housing, forming a ball joint, according to one embodimentof the disclosure;

FIG. 5 also illustrates an adjustment arm of an adjustment systemreleasably locked with a locking member of the adjustment system;

FIGS. 6A-6B illustrate a gas exhaust system for removing exhaled gasaway from a patient, according to one embodiment of the disclosure; and

FIGS. 7A-7D illustrate the operation of an adjustment system foradjusting the fit of a mask apparatus against a patient's head (e.g.,for adjusting the fit of a mask cushion against the patient's face),according to one embodiment of the disclosure.

DETAILED DESCRIPTION OF THE DRAWING

Selected embodiments of the disclosure may be understood by reference,in part, to FIGS. 1-7D, wherein like numbers refer to same and likeparts. The present disclosure relates generally to mask apparatuses forbreathing assistance systems (e.g., ventilators, CPAP devices, or BiPAPdevices).

In some embodiments, a mask apparatus may include a cushion forproviding a seal against a patient's face, a housing configured tosupport the cushion, and a ball joint disposed in the housing thatallows multi-axial rotation of a gas delivery conduit relative to thehousing. The gas delivery conduit may be configured to deliver gasthrough the housing for delivery to the patient. The ball joint mayinclude a ball member positioned in an opening formed in the housing,and a mounting system configured to secure the ball member in thehousing opening such that the housing, the ball member, and the mountingsystem define a ball joint allowing the ball member to rotate aboutmultiple axes relative to the housing and the mounting system. The ballmember may have a passageway extending therethrough for communicatinggas from the gas delivery conduit into the housing and toward thepatient.

In some embodiments including a ball joint, a gas exhaust system may bedefined by or associated with the ball joint. For example, one or moreexhaust passageways may be defined between an outer surface of the ballmember and the housing opening, wherein the one or more exhaustpassageways are configured for communicating exhaust gas away from thepatient.

In some embodiments, a mask apparatus may include a cushion forproviding a seal against a patient's face, a housing configured tosupport the cushion, and an adjustment system supported by the housingand configured to adjust the fit of the mask apparatus (e.g., thecushion) against the face. For example, the adjustment system mayinclude an adjustment arm that interrelates with a locking member toadjust and/or lock the angle of the adjustment arm relative to thehousing. The adjustment arm may be rotatably coupled to the housing at afirst end and may be coupled to a head gear (e.g., a head strap) at asecond, free end. The adjustment arm may rotate relative to the housingto adjust a distance between the free end of the adjustment arm and thepatient's head (e.g., proximate the forehead). The locking member may becoupled to the housing and may be configured to secure the adjustmentarm in one of a plurality of predetermined rotational positions withrespect to the housing.

A mask apparatus according to the present disclosure may include anyone, some, or all of such features. For example, a mask apparatus mayinclude a ball joint, an exhaust system associated with the ball joint,and an adjustment system. As another example, a mask apparatus mayinclude a ball joint, an exhaust system associated with the ball joint,but no adjustment system. As another example, a mask apparatus mayinclude a ball joint, an adjustment system, and an exhaust systemunrelated to the ball joint. As another example, a mask apparatus mayinclude an adjustment system, but not ball joint.

FIG. 1 illustrates an example breathing assistance system 10, accordingto one embodiment of the disclosure. Breathing assistance system 10 maybe generally configured to provide breathing assistance (e.g., providingventilation and/or treating an apnea or other breathing condition) to apatient 12. Breathing assistance system 10 may include a gas deliverysystem 14, a mask apparatus 16, and a connection system 18 between gasdelivery system 14 and mask apparatus 16.

Gas delivery system 14 may include any device or devices configured togenerate, supply, and/or deliver gas (e.g., pressurized air) towardpatient 12 via mask apparatus 16. For example, gas delivery system 14may comprise a device capable of generating pressurized air (e.g., aventilator, CPAP system, or BiPAP system), a wall outlet through whichpressurized air may be supplied (e.g., in a hospital or clinic), one ormore tanks of compressed gas, a compressor, or any other suitable sourceof pressurized or non-pressurized gas. As used herein, the term “gas”may refer to any one or more gases and/or vaporized substances suitableto be delivered to and/or from a patient via one or more breathingorifices (e.g., the nose and/or mouth), such as air, nitrogen, oxygen,any other component of air, CO₂, vaporized water, vaporized medicines,and/or any combination of two or more of the above, for example. Theterm “patient” may refer to any person or animal that may receivebreathing assistance from system 10, regardless of the medical status,official patient status, physical location, or any other characteristicof the person. Thus, for example, patients may include persons underofficial medical care (e.g., hospital patients), persons not underofficial medical care, persons receiving care at a medical carefacility, persons receiving home care, etc.

Mask apparatus 16 may be generally configured to deliver gas supplied bygas delivery system 14 to patient 12 and/or to communicate exhaust gasaway from patient 12. In various embodiments, mask apparatus 16 mayinclude one, some or all of the following features:

(a) a cushion 20 configured to provide a seal against the patient's face(e.g., around the patient's nose and/or mouth);

(b) a housing 22 configured to support cushion 20;

(c) a gas delivery conduit 24 configured to communicate gas from gasdelivery system toward cushion 20;

(d) a ball joint 26 configured to provide a flexible, movable, and/oradjustable connection between housing 22 and gas delivery conduit 24;

(e) a gas exhaust system 28 configured to remove exhaled gas away frompatient 12;

(f) a headgear 30 configured to secure mask apparatus 16 on thepatient's head and/or to secure cushion 20 against the patient's face;and/or

(g) an adjustment system 32 for adjusting the fit of mask apparatus 16against the patient's head (e.g., for adjusting the fit of cushion 20against the patient's face).

Mask apparatus 16 may also include any other suitable components, e.g.,a forehead cushion or other forehead support system, one or moreadditional adjustment systems, connection members, and/or conduits forcommunicating gas toward and/or away from patient 12.

Mask apparatus 16 may be coupled to gas delivery system 14 by connectionsystem 18. Connection system 18 may include any one or more conduits(e.g., one or more flexible hoses and/or rigid conduits) forcommunicating gas from gas delivery system 14 to mask apparatus 16. Insome embodiments, connection system 18 may be coupled to deliveryconduits 24 of mask apparatus 16. When assembled, breathing assistancesystem 10 may define one or more gas delivery passageways from gasdelivery system 14 to patient 12, passing through connection system 18,mask apparatus 16, and/or one or more other components of system 10.Such passageways may be used to deliver gas from gas delivery system 14to patient 12. In addition, in some embodiments, mask apparatus 16and/or connection system 18 may include or define one or morepassageways for communicating exhaled gas away from patient 12.

Cushion 20 may comprise any structure suitable for contacting and/orproviding a seal against a patient's face. In some embodiments, cushion20 may be configured to surround, cover, or interface with the noseand/or the mouth. For example, cushion 20 may comprise a nasal cushionconfigured to fit around the nose, a mouth cushion configured to fitaround the mouth, a face cushion configured to fit around both the noseand mouth, or nasal pillows configured to directly interface with thenostrils.

Cushion 20 may be formed from any suitable materials, e.g., materialssuitable for forming a seal with the patient's face. In someembodiments, cushion 20 may be formed from relatively flexible ordeformable materials, such as flexible or deformable plastic, rubber,polymer, silicon, or gel, for example. In some embodiments, cushion 20may have one or more membranes which may be contoured to provide a sealagainst the patient's face. In other embodiments, cushion 20 may includeone or more inflatable portions. Cushion 20 may have any suitable shapeand/or cross-section. In some embodiments in which cushion 20 isconfigured to fit around the patient's nose (e.g., as shown in FIG. 1),cushion 20 may have a generally triangular shape.

Housing 22 may comprise any one or more components of mask apparatus 16configured to support (directly or indirectly) cushion 20. For example,housing 22 may comprise a shell structure, a support member, a framemember, a base member, a connection member, an arm member, or a conduit.In the example embodiment shown in FIG. 1, housing 22 comprises a maskshell or frame to which cushion 20 is directly attached.

In addition, housing 22 may house or form a portion of ball joint 26. Asdiscussed below with reference to FIG. 2, housing may define an opening34 in which a ball member 36 may be positioned such that ball member 36may rotate about multiple axes relative to housing 22.

In addition, housing 22 may provide or help define gas exhaust system28. For example, as discussed below with reference to FIGS. 2 and 6A-6B,one or more exhaust passageways 38 may be defined between opening 34 ofhousing 22 and an outer surface of ball member 36. Such exhaustpassageways 38 may be configured to communicate exhaust gas from patient12 (e.g., CO₂) away from patient 12.

In addition, housing 22 may support (directly or indirectly) adjustmentsystem 32 for adjusting the fit of mask apparatus 16 against thepatient's head (e.g., for adjusting the fit of cushion 20 against thepatient's face). In the embodiment shown in FIG. 1, adjustment system 32may include an adjustment arm 40 and a locking member 42 supported byhousing 22, which may interact in order to adjust the distance between afree end of adjustment arm 40 and the patient's head.

In addition to supporting adjustment system 32 that is coupled toheadgear 30, housing 22 may be further configured to support headgear30. For example, housing 22 may include one or more headgear attachmentmembers 46 for securing headgear 30. In the illustrated embodiment,housing 22 includes a headgear attachment member 46 located on eachlateral side of housing 22. A head strap may be adjustably attached toeach headgear attachment member 46 to help secure mask apparatus 16against the patient's head.

Housing 22 may be a single, integrated component, or may includemultiple components coupled together.

Cushion 20 may be directly or indirectly coupled to housing 22. In someembodiments, cushion 20 is releasably coupled to housing 22 such thatcushion 20 may be removed from, and reattached to, housing 22. Cushion20 may be releasably coupled to housing 22, directly or indirectly, inany suitable manner. For example, cushion 20 may be releasably coupledto housing 22 in any manner disclosed in co-pending U.S. patentapplication Ser. No. 11/469,260, filed Aug. 31, 2006, and entitled“Patient Interface Assembly for a Breathing Assistance System,” which ishereby incorporated by reference. As another example, cushion 20 may bereleasably coupled to housing 22 using any suitable clips or otherconnectors.

Gas delivery conduit 24 may comprise any one or more conduits configuredto communicate gas from gas delivery system 14 toward cushion 20. Suchconduits may include, e.g., one or more flexible hoses and/or rigidconduits. Gas delivery conduit 24 may be coupled at a first end toconnection system 18 (e.g., a breathing circuit), and may be directly orindirectly coupled at a second end to housing 22 and/or cushion 20 inorder to deliver gas to patient 12 via cushion 20. In the embodimentshown in FIG. 1, gas delivery conduit 24 is removably coupled to balljoint 26. As discussed below, ball member 36 includes an openingextending therethrough such that gas may be delivered from gas deliveryconduit 24, through the opening in ball member 36, through housing 22and cushion 20, and to patient 12.

In some embodiments, gas delivery conduit 24 may be secured to thepatient's head. For example, as shown in FIG. 1, gas delivery conduit 24may be extend upwardly in front of the patient's head and may bereleasably secured to headgear 30 near the top of the patient's head.

Ball joint 26 may be configured to provide a flexible, movable, and/oradjustable connection between gas delivery conduit 24 and housing 22. Insome embodiments, ball joint 26 may provide for multi-axial rotation ofgas delivery conduit 24 relative to housing 22. In the illustratedembodiment, ball joint 26 includes ball member 36 positioned in opening34 formed in housing 22. Ball member 36 may be secured against housing22 may a mounting system 50 (discussed below with reference to FIG. 2).Together, ball member 36, housing 22, and mounting system 50 may formball joint 26.

Gas exhaust system 28 may be configured to remove exhaled gas away frompatient 12. In the illustrated embodiments, gas exhaust system 28includes one or more exhaust passageways 38 defined between opening 34of housing 22 and an outer surface of ball member 36. Such exhaustpassageways 38 may be configured to communicate exhaust gas from patient12 (e.g., CO₂) away from patient 12. In some embodiments, opening 34 maydefine a perimeter including one or more contact portions alternativewith one or more non-contact portions. The non-contact portions may beportions of the perimeter of opening 34 that do not contact ball member36, thus defining an exhaust passageway 38 between ball member 36 andopening 34. Gas exhaust system 28 is discussed in greater detail belowwith reference to FIGS. 6A-6B.

Headgear 30 may be configured to secure mask apparatus 16 on thepatient's head and/or to secure cushion 20 against the patient's face.Headgear 30 may include any one or more components. For example,headgear 30 may include a head strap 60 including multiple strapportions 62 coupled to mask apparatus 16 at various locations. In theillustrated embodiment, head strap 60 includes: (a) a left side strapportion 62 a extending around the left side of the patient's face andsecured to a left headgear attachment member 46 a, (b) a right sidestrap portion 62 b extending around the right side of the patient's faceand secured to a right headgear attachment member 46 b, and (c) a topstrap portion 62 c extending over the top of the patient's head andsecured to a free end of adjustment arm 40.

Strap portions 62 may be coupled to mask apparatus 16 in any suitablemanner. For example, as shown in FIG. 1, each strap portion 62 may bethreaded through an opening formed in a component of mask apparatus 16,and folded back and attached to itself using hook and loop fasteners.Thus, each strap portion 62 may me adjustable as desired by patient 12.Each strap portion 62 may be integrated with or coupled to other strapportions 62 in any suitable manner, e.g., using hook and loop fastenersor other connection devices. In one embodiment, strap portions 62 a, 62b, and 62 c are integrated in a single piece head strap 60. Strapportions 62 may be formed from any one or more flexible and/or elasticmaterials. For example, strap portions 62 may be formed from elastomericmaterials, neoprene, fabric, or other similar materials.

Adjustment system 32 may be configured for adjusting the fit of maskapparatus 16 against the patient's head (e.g., for adjusting the fit ofcushion 20 against the patient's face). As discussed above, adjustmentsystem 32 may include an adjustment arm 40 and a locking member 42supported by housing 22. At least one of adjustment arm 40 and a lockingmember 42 may be configured for attachment to headgear 30, and may beadjusted relative to housing 22 in order to adjust the fit of maskapparatus 16 against the patient's head. For example, as discussed belowwith reference to FIGS. 7A-7B, adjustment arm 40 may be rotatablycoupled to housing 22 such that adjustment arm 40 may rotate asindicated by arrow 66, in order to adjust the distance between a freeend of adjustment arm 40 and the patient's head. Locking member 42 mayinteract with adjustment arm 40 in order to lock adjustment arm 40 inone of a plurality of rotational positions.

As discussed above, adjustment system 32 may be used for adjusting thefit of mask apparatus 16 against the patient's head. For example, maskapparatus 16 may be adjusted using adjustment system 32 in order toproperly secure mask apparatus 16 onto the patient's head, and/or toprovide a proper seal between cushion 20 and the patient's face. In thismanner, adjustment system 32 may be used to adjust mask apparatus 16 tofit a variety of patient's having various head or face shapes and/orsizes. For example, mask apparatus 16 may be adjusted to fit bothchildren and adults.

FIG. 2 illustrates an exploded view of a portion of mask apparatus,indicating the assembly of housing 22, ball member 36, and mountingsystem 50 to form ball joint 26, according to one embodiment of thedisclosure. Ball member 36 may be inserted through an opening 34 formedin housing 22. Mounting system 50 may be configured to secure ballmember 36 in housing opening 34 such that housing 34, ball member 36,and mounting system 50 form ball joint 26 allowing ball member 36 torotate relative to the housing 22 and mounting system 50.

Ball member 36 may include a cylindrical portion 52 configured to becoupled to gas delivery conduit 24 and a spherical portion 54 positionedin opening 34 in housing 22. Ball member 36 may include an opening 56extending therethrough such that when mask apparatus is assembled andsecured to patient 12, gas may be delivered from gas delivery conduit24, through opening 56, through housing 22 and cushion 20, and topatient 12. Ball member 36 may be a single integrated component, or mayinclude multiple components coupled together in any suitable manner. Forexample, in one embodiment, ball member 36 includes (a) a body portion57 that defines cylindrical portion 52 and opening 56, and (b) ahemispherical cap portion 58 that slides over cylindrical portion 52 andcooperates with a hemispherical portion of body portion 57 to definespherical portion 54.

Mounting system 50 may comprise any one or more mounting membersconfigured to secure ball member 36 in housing opening 34. One or moreof such mounting members may be directly or indirectly coupled tohousing 22. In addition, such one or more mounting members may define anopening into which a portion of ball member 36 may be positioned.

In the illustrated embodiment, mounting system 50 comprises a mountingplate 70 including a mounting plate opening 72. Once mounting plate 70is assembled with housing 22, a first, front portion of ball member 36may extend through housing opening 34 and a second, rear portion of ballmember 36 may extend through mounting plate opening 34.

Mounting system 50 may be releasably attached to housing 22 such thatball joint 26 may be assembled and disassembled, and such that ballmember 36 may be removed from housing opening 34. Mounting system 50 maybe releasably attached to housing 22 in any suitable manner. In someembodiments, mounting system 50 may include a securing system 74 forreleasably securing mounting system 50 to housing 22. For example, inthe illustrated embodiment, mounting plate 70 may include one or moresecuring members 76 configured for releasable attachment to housing 22.As discussed below with reference to FIGS. 4A-4C, securing members 76may be manually moved from a first position for securing mounting plate70 to housing 20 and a second position for releasing mounting plate 70from housing 22.

As discussed above, gas exhaust system 28 may include one or moreexhaust passageways 38 defined between housing opening 34 and an outersurface of ball member 36 for communicating exhaust gas away frompatient 12. As shown in FIG. 2, opening 34 may define a perimeterincluding one or more contact portions 80 alternating with one or morenon-contact portions 82. Contact portions 80 generally contact ballmember 36 when ball joint 26 is assembled. Non-contact portions 82generally do not contact ball member 36, thus defining exhaustpassageways 38 between ball member 36 and opening 34. In thisembodiment, three contact portions 80 are alternated with threenon-contact portions 82, thus defining three exhaust passageways 38. Inother embodiments, mask apparatus 16 may include any other number and/orconfiguration of contact portions 80, non-contact portions 82, and/orexhaust passageways 38.

As shown in FIG. 2, each non-contact portion 82 may be a cut-away orreceded portion from the perimeter of opening 34. Each contact portion80 and/or non-contact portion 82 may have any suitable size, shape,and/or configuration. For example, contact portions 80 and/ornon-contact portions 82 may be sized, shaped, and/or configured to formexhaust passageways 38 that allow a particular flow rate of exhaust gasthrough such passageways 38. As another example, contact portions 80and/or non-contact portions 82 may be sized, shaped, and/or configuredto form exhaust passageways 38 that direct exhaust gasses in one or moreparticular direction.

Mounting system 50 may define one or more pathways for exhaust gas to becommunicated from patient 12 to exhaust passageways 38. In theillustrated embodiment, mounting plate 70 may include or define one ormore openings allowing exhaust gas from patient 12 to pass throughtoward exhaust passageways 38. For example, mounting plate 70 may beshaped and/or sized to define one or more passages between the outerperimeter of mounting plate 70 and an inner surface of housing 22. Asanother example, mounting plate 70 may define one or more passagesallowing exhaust gas to pass through toward exhaust passageways 38. Inthe illustrated embodiment, each securing member 76 defines an opening84 allowing exhaust gas to pass through toward exhaust passageways 38.As another example, mounting plate 70 may include one or more openings86 allowing exhaust gas to pass through toward exhaust passageways 38.

Mounting system 50 may also include one or more alignment devices foraligning mounting system 50 with housing 22. In this embodiment,mounting plate 70 includes one or more alignment holes 88 configured toreceive one or more alignment members for aligning mounting plate 70with housing 22, as discussed below with reference to FIG. 3.

One or more stiffening members 92 may disposed proximate the housingopening 34 for providing structural integrity around opening 34 (e.g.,to resist deformation of housing opening 34). Stiffening members 92 maybe integrated with or coupled to housing 22 in any suitable manner. Inthe illustrated embodiment, housing 22 includes an integrated stiffeningmember 92 proximate each contact portion 80 for providing structuralintegrity around opening 34.

Gas exhaust system 28 is further discussed below with reference to FIGS.6A-6B.

FIG. 2 also illustrates adjustment system 32 for adjusting the fit ofmask apparatus 16 against the patient's head (e.g., for adjusting thefit of cushion 20 against the patient's face). Adjustment arm 40 andlocking member 42 may be coupled to housing 22. In some embodiments,adjustment arm 40 and/or locking member 42 are formed integral withhousing 22. For example, in the illustrated embodiment, adjustment arm40 is integrally coupled to housing 22 by a living hinge, which allowsadjustment arm 40 to rotate relative to housing 22 in the directionindicated by arrow 66. In addition, locking member 42 may be integrallycoupled to housing 22 by a living hinge or a less flexible joint thatallows some flexing of locking member 42 relative to housing 22, butless than that of adjustment arm 40.

Adjustment arm 40 and locking member 42 may interact with adjustment arm40 in any suitable manner to allow adjustment arm 40 to be releasablylocked in a plurality of different positions. In the illustratedembodiment, adjustment arm 40 includes a slot 100 configured to receivelocking member 42. Locking member 42 may slide through slot 100 asadjustment arm 40 rotates along path 66.

Locking member 42 may include one or more first locking elements 104,and adjustment arm 40 may include one or more second locking elements106 configured to interact with first locking elements 104 to releasablysecure adjustment arm 40 in one of multiple different predeterminedrotational positions. Locking elements 104 and 106 are betterillustrated in FIGS. 5 and 7A-7D, which are discussed in greater detailbelow.

Locking elements 104 and 106 may include any elements configured tointeract to releasably couple adjustment arm 40 and locking member 42.For example, locking elements 104 and/or 106 may comprise any suitableprojections, bumps, teeth, indentations, holes, grooves, clips, hooks,latches, or any other suitable members or devices.

In the illustrated embodiment, locking member include three projections(e.g., bumps) 104 and adjustment arm 40 includes three indentations oropenings 106. Each indentation 106 is configured to receive acorresponding projection 104 to lock adjustment arm 40 in a particularrotational position. Thus, adjustment arm 40 may be releasably locked inthree predetermined rotational positions. In some embodiments,adjustment arm 40 may be manually moved between the three lockingpositions, which may include manual manipulation of adjustment arm 40and/or locking member 42. For example, in one embodiment, if adjustmentarm 40 is locked in a first position in which a first projection 104 issecured in a first indentation 106, adjustment arm 40 and locking member42 may be flexed laterally in opposite directions to release the firstprojection 104 from the first indentation 106. Adjustment arm 40 maythen be rotated along path 66 until a second projection 104 is receivedin a second indentation 106 to lock adjustment arm 40 in a secondrotational position.

Adjustment system 32 may also include one or more stop elements 112, 114to limit the rotation of adjustment arm 40 in one or more directions. Inthe illustrated embodiment, locking member 42 includes a hook portionthat acts as a first stop 112 to limit the rotation of adjustment arm 40in a direction away from the patient's face. A second stop 114 may belocated proximate the base of locking member 42 to limit the rotation ofadjustment arm 40 in a direction toward the patient's face.

FIG. 3 illustrates mask apparatus 16, with mounting plate 70 aligned forattachment to housing 22, according to one embodiment of the disclosure.In this illustration, ball member 36 has been inserted in housingopening 34, and mounting plate 70 may be coupled to housing 22 to secureball member 36 between housing 22 and mounting plate 70 to form balljoin 26.

In this embodiment, mounting plate 70 has a substantially triangularshape and includes three securing members 76 positioned around theperimeter of plate 70. Each securing member 76 may be configured to bereleasably coupled to a corresponding attachment member 120 for couplingplate 70 to housing 22. In this embodiment, three attachment members 120are formed integral with, or coupled to, an inner surface of housing 22.As discussed with reference to FIGS. 4A-4C, each securing member 76 maycomprise a flexible arm or clip that may be manually flexed between afirst position for attaching that securing member 76 to thecorresponding attachment member 120 and a second position for releasingthe securing member 76 from the attachment member 120.

In addition, one or more alignment members 124 may be provided foraligning mounting plate 70 with housing 22. In this embodiment, analignment member 124 is configured to fit within an alignment hole 88formed in mounting plate 70 in order to align mounting plate 70 withhousing 22.

FIGS. 4A-4C illustrates a detailed view of an example securing member 76and corresponding attachment member 120 for securing mounting plate 70to housing 22, according to one embodiment of the disclosure. Securingmember 76 may comprise a flexible arm or clip that may be manuallyflexed to attach or detach securing member 76 from attachment member120. In this embodiment, securing member 76 includes a forked, or arced,end portion 130 that may be configured to interlock with (e.g., snapinto) attachment member 120. Attachment member 120 may comprise a peg orother element having an undercut boss region 132 configured to receiveforked end portion 130 of securing member 76. To attach mounting plate70 to housing 22, securing members 76 may be flexed to move end portions130 inwardly toward the center of mounting plate 70, plate 70 may thenbe aligned (e.g., using alignment member 124 and alignment hole 88) andpressed against housing 22, and securing members 76 may then be releasedsuch that end portions 130 of securing members 76 interlock withundercut boss region 132 of attachment members 120. It should beunderstood that any other suitable members or devices may be used forreleasably attaching mounting plate 70 to housing 22.

FIG. 5 illustrates the inside of mask apparatus 16 with mounting plate70 secured to housing 22, thus forming ball joint 26, according to oneembodiment of the disclosure. A rear portion of ball member 36 mayextend into and/or through opening 72 formed in mounting plate 70. Asdiscussed above, openings 86 in mounting plate 70 may providepassageways for exhaust gas to pass from patient 12 to exhaustpassageways 38 (shown in FIGS. 2 and 6A-6B).

FIG. 5 also illustrates adjustment arm 40 releasably locked with lockingmember 42. As discussed above, in this embodiment, locking member 42includes three projection 104 configured to lock with three indentations106 formed in adjustment arm 40. In this illustration, a firstprojection (not shown) is received in a first indentation 106 a toreleasably secure adjustment arm 40 in a first of three predeterminedrotational positions. FIG. 5 also illustrates second stop 114 (discussedabove regarding FIG. 2) located proximate the base of locking member 42for limiting the rotation of adjustment arm 40 in a direction toward thepatient's face.

FIGS. 6A-6B illustrate gas exhaust system 28 for removing exhaled gasaway from patient 12, according to one embodiment of the disclosure. Asdiscussed above, gas exhaust system 28 may include one or more exhaustpassageways 38 defined between housing opening 34 and an outer surfaceof ball member 36 for communicating exhaust gas away from patient 12. Insome embodiments, opening 34 may define a perimeter including one ormore contact portions 80 alternating with one or more non-contactportions 82. Contact portions 82 generally contact ball member 36 whenball joint 26 is assembled. Non-contact portions 82 generally do notcontact ball member 36, thus defining exhaust passageways 38 betweenball member 36 and opening 34. In this embodiment, three contactportions 82 are alternated with three non-contact portions 82, thusdefining three exhaust passageways 38. In other embodiments, maskapparatus 16 may include any other number and/or configuration ofcontact portions 82, non-contact portions 82, and/or exhaust passageways38.

As shown in FIGS. 6A-6B, each non-contact portion 82 may be a cut-awayor receded portion from the perimeter of opening 34. Each contactportion 80 and/or non-contact portion 82 may have any suitable size,shape, and/or configuration, e.g., to form exhaust passageways 38 havingdesired shapes, sizes, and/or configurations. For example, a width 140and depth 142 of each non-contact portion 82 may be selected fordefining exhaust passageways 38 that (a) allow a particular flow rate ofexhaust gas through passageways 38, (b) provide for particular soundcharacteristics for gasses flowing through passageways 38, and/or (c)direct exhaust gasses in one or more particular direction.

For example, width 140 and depth 142 of each non-contact portion 82 maybe sized to provide a total gas passageway area of about 0.13-0.25 cm².As another example, width 140 and depth 142 of each non-contact portion82 may be sized to provide a gas flow of about 10-40 liter/min at 10 cmH₂O. In some embodiments, width 140 and depth 142 of each non-contactportion 82 may be sized to provide a gas flow of about 15-25 liter/minat 10 cm H₂O. In one example embodiment, each non-contact portion 82 hasa width 140 of about 0.5 inch and a depth 142 of about 0.015 inch.

FIGS. 7A-7D illustrate the operation of adjustment system 32 foradjusting the fit of mask apparatus 16 against the patient's head (e.g.,for adjusting the fit of cushion 20 against the patient's face),according to one embodiment of the disclosure. As discussed above,adjustment arm 40 may be rotatably coupled to housing 22 such thatadjustment arm 40 may rotate as indicated by arrow 66, in order toadjust the distance between a free end 150 of adjustment arm 40 and thepatient's head. Adjustment arm 40 and locking member 42 may interactwith adjustment arm 40 in any suitable manner to allow adjustment arm 40to be releasably locked in a plurality of different positions. In theillustrated embodiment, locking member 42 slides through slot 100 formedin adjustment arm 40.

In this embodiment, locking member 42 includes three locking elements104, and adjustment arm 40 includes three locking elements 106configured to interact with locking elements 104 to releasably secureadjustment arm 40 in three predetermined rotational positions. Inaddition, adjustment system 32 may include one or more stop elements112, 114 to limit the rotation of adjustment arm 40 in one or moredirections. In the illustrated embodiment, locking member 42 includes afirst stop 112 (e.g., a hook portion) to limit the rotation ofadjustment arm 40 in a first direction indicated by arrow 152, and asecond stop 114 proximate the base of locking member 42 to limit therotation of adjustment arm 40 in a second direction indicated by arrow154.

FIG. 7A illustrates adjustment arm 40 free from locking arm 40.

FIGS. 7B-7D interacting with locking arm 40. To move adjustment arm 40from the position shown in FIG. 7A to any of the positions shown inFIGS. 7B-7D, locking member 42 may be inserted through slot 100 formedin adjustment arm 40. In one embodiment, in order to position lockingmember 42 within slot 100, a user may flex locking member 42 slightlytoward adjustment arm 40 such that the free end of locking member 42fits within slot 100. Adjustment arm 40 may then be rotated along path66 between the multiple different locking positions. To releaseadjustment arm 40 from locking member 42 (i.e., to return adjustment arm40 to the position shown in FIG. 7A), the user may again flex lockingmember 42 slightly toward adjustment arm 40 such that the free end oflocking member 42 may be removed from slot 100.

As shown in FIGS. 7B-7D, adjustment arm 40 may be secured in any of thethree predetermined rotational positions using locking elements 104 and106, positioned against first stop 112, or positioned against secondstop 114. In particular, FIG. 7B illustrates adjustment arm 40 locked ina middle locking position; FIG. 7C illustrates adjustment arm 40positioned against first stop 112; and FIG. 7D illustrates adjustmentarm 40 positioned against second stop 114. Adjustment arm 40 may bemanually moved between the three locking positions and two stoppositions. As discussed above, in one embodiment, in order to moveadjustment arm 40 may be manually moved between the three lockingpositions, adjustment arm 40 and locking member 42 may be flexedlaterally in opposite directions to release a particular projection 104from a corresponding indentation 106. Adjustment arm 40 may then berotated along path 66 until another projection 104 is received inanother indentation 106 to lock adjustment arm 40 in a differentrotational position.

It will be appreciated that while the disclosure is particularlydescribed in the context of breathing assistance systems, theapparatuses, techniques, and methods disclosed herein may be similarlyapplied in other contexts. Additionally, it should be understood thatvarious changes, substitutions and alterations can be made hereinwithout departing from the spirit and scope of the disclosure asillustrated by the following claims.

1. A gas exhaust system for a mask apparatus for use in a breathingassistance system, the gas exhaust system comprising: a housing forsupporting a cushion configured to provide a seal against a patient'sface, the housing defining a housing opening; a ball member secured inthe housing opening such that the ball member may rotate relative to thehousing; and one or more exhaust passageways defined between an outersurface of the ball member and the housing opening, the one or moreexhaust passageways configured for communicating exhaust gas away fromthe patient.
 2. A gas exhaust system according to claim 1, wherein forany rotational position of the ball member relative to the housing, atleast one exhaust passageway is open.
 3. A gas exhaust system accordingto claim 1, wherein: the housing opening defines a perimeter includingone or more contact portions and one or more non-contact portionsalternating around the perimeter; the one or more contact portions ofthe perimeter are configured to contact the ball member; and the one ormore non-contact portions of the perimeter at least partially define theone or more exhaust passageways.
 4. A gas exhaust system according toclaim 3, wherein the perimeter of the housing opening includes threecontact portions and three non-contact portions, each of the threenon-contact portions at least partially defining an exhaust passageway.5. A gas exhaust system according to claim 1, including three exhaustpassageways defined between an outer surface of the ball member and thehousing opening.
 6. A gas exhaust system according to claim 1, whereinthe ball member includes a ball member opening extending through theball member and configured for communicating gas toward the patient. 7.A gas exhaust system according to claim 6, wherein the ball memberopening has a smaller diameter than the housing opening.
 8. A gasexhaust system according to claim 1, further comprising a mountingsystem configured to secure the ball member in the housing opening suchthat the housing, the ball member, and the mounting system define a balljoint.
 9. A gas exhaust system according to claim 8, wherein: themounting system is coupled to the housing and defines a mounting systemopening; and a first portion of the ball member extends into the housingopening and a second portion of the ball member extends into themounting system opening such that the ball member is secured between themounting system and the housing.
 10. A gas exhaust system according toclaim 8, wherein the mounting system defines one or more mounting systemexhaust openings providing one or more pathways for exhaust gas to becommunicated to the one or more exhaust passageways.
 11. A gas exhaustsystem according to claim 10, wherein the mounting system comprises amounting plate including a mounting member opening and one or moremounting system exhaust openings separate from the mounting memberopening.
 12. A gas exhaust system according to claim 8, wherein themounting system comprises multiple mounting members defining a mountingmember opening.
 13. A gas exhaust system according to claim 8, whereinthe mounting system is releasably coupled to the housing such that theball may be removed from the housing opening.
 14. A gas exhaust systemaccording to claim 8, further comprising a securing system for securingthe mounting system to the housing; wherein the securing system definesone or more securing system openings providing one or more pathways forexhaust gas to be communicated to the one or more exhaust passageways.15. A gas exhaust system according to claim 14, wherein the securingsystem includes one or more securing elements configured to be manuallymoved from a first position for securing the mounting system to thehousing and a second position for releasing the mounting system from thehousing.
 16. A breathing assistance system, comprising: a gas deliveryapparatus configured to deliver gas toward a patient; a mask apparatusin fluid communication with the gas delivery apparatus, the maskapparatus including a gas exhaust system for exhausting gas away fromthe patient, the gas exhaust system comprising: a housing for supportinga cushion configured to provide a seal against the patient's face, thehousing defining a housing opening; a ball member secured in the housingopening such that the ball-member may rotate relative to the housing;and one or more exhaust passageways defined between an outer surface ofthe ball member and the housing opening, the one or more exhaustpassageways configured for communicating exhaust gas away from thepatient.
 17. A breathing assistance system according to claim 16,wherein: the housing opening defines a perimeter including one or morecontact portions and one or more non-contact portions alternating aroundthe perimeter; the one or more contact portions of the perimeter areconfigured to contact the ball member; and the one or more non-contactportions of the perimeter at least partially define the one or moreexhaust passageways.
 18. A breathing assistance system according toclaim 16, wherein the ball member includes a ball member openingextending through the ball member and configured for communicating gastoward the patient.
 19. A breathing assistance system according to claim16, wherein the gas exhaust system further includes a mounting systemconfigured to secure the ball member in the housing opening such thatthe housing, the ball member, and the mounting system define a balljoint.
 20. A breathing assistance system according to claim 19, wherein:the mounting system is coupled to the housing and defines a mountingsystem opening; and a first portion of the ball member extends into thehousing opening and a second portion of the ball member extends into themounting system opening such that the ball member is secured between themounting system and the housing.
 21. A breathing assistance systemaccording to claim 19, wherein the mounting system defines one or moremounting system exhaust openings providing one or more pathways forexhaust gas to be communicated to the one or more exhaust passageways.22. A gas exhaust system for a mask apparatus for use in a breathingassistance system, the gas exhaust system comprising: housing means forsupporting a cushion configured to provide a seal against a patient'sface, the housing means defining a housing means opening; ball meanssecured in the housing means opening such that the ball means may rotaterelative to the housing means; exhaust communicating means forcommunicating exhaust gas away from the patient, the exhaustcommunicating means defined between an outer surface of the ball meansand the housing means opening; and mounting means for securing the ballmeans in the housing means such that the housing means, the ball means,and the mounting means define a ball joint.